Modular Tooling Apparatus Having Serrated Teeth for Orbital and Linear Adjustment

ABSTRACT

A modular tooling apparatus providing orbital adjustment of a modular tool. The modular tooling apparatus includes a base coupling, a first linkage member, and a second linkage member. The base coupling is connectible to a manipulator. The first linkage member is adjustably connected to the base coupling for rotational adjustment about a first axis. The second linkage member is adjustably connected to the first linkage member for rotational adjustment about a second axis. The rotational adjustment of the first linkage member about the first axis and the rotational adjustment of the second linkage member about the second axis combine to provide more orbital positions than the rotational adjustment of the first linkage member about the first axis or the rotational adjustment of the second linkage member about the second axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/440,464, which was filed on Feb. 8, 2011.

FIELD OF THE INVENTION

The present invention relates to a modular tooling apparatus havingorbital and linear adjustments, and in particular, a modular toolingapparatus having serrated teeth that provide for accurate and repetitiveorbital, rotational, and linear adjustment of modular tooling connectedto the modular tooling apparatus.

BACKGROUND

With the advent of mechanical manipulators and robotic arms, varioustooling assemblies and work piece handling devices have been designed toquickly connect and disconnect to mechanical manipulators and roboticarms so that a variety of modular tooling assemblies can be utilizedwith the same manipulator. Flexibility and adjustability are preferablydesigned into the tooling assemblies so that the tooling assemblies canbe configured for a variety of work piece configurations. Previoustooling assemblies have utilized various sections of tubinginterconnected by various brackets and mounts for fixturing a variety ofwork pieces, but such designs are typically rigid and provide little orno adjustment in the tooling assembly. Other designs have utilizedextrusions or slide mounts to allow the sections of tubing to beadjusted along a linear path of travel, but such designs have a limitedamount of flexibility, as they provide only one degree or axis ofadjustment.

Other known designs have utilized ball mounts to provide rotational ororbital adjustment of the tubing. Such ball mounts typically provide abracket that receives and clamps a spherical ball through the use of thebracket and a conventional fastener. Due to the configuration of theclamps, such ball mounts typically do not provide 360° rotationalmovement. In addition, these designs are susceptible to slipping,especially when such tooling mounts are exposed to various grease andoils, as well as random forces that are common in an industrialenvironment. If the ball mount slips, the work piece-handling boom maybecome misaligned with respect to the work piece thereby requiring theworkstation to be shut down and readjusted. These shut downs createinefficiencies that are undesirable in an industrial environment.

Other modular tooling apparatuses have utilized opposing serrated teethto provide rotational or orbital adjustment of a first and secondcoupling about an axis of rotation. The serrated teeth providepredetermined rotational adjustment of the first and second couplingsrelative to one another while assuring that the couplings will notrotate or slip with respect to one another when the serrated teeth areengaged in a tightened position. A disadvantage to the serrated teeth isthat they provide a predetermined number of set positions, therebylimiting the possible positions of the modular tooling apparatus.Another disadvantage in the serrated teeth adjustment is that theserrated teeth must be completely disengaged from one another in orderto adjust the position of the couplings. Thus, adjusting the couplingsby rotating the serrated teeth relative to one another can be a rathercumbersome and difficult task. Since there may be several pieces ofmodular tooling connected to the serrated teeth, it may become even moredifficult to adjust the positioning of the serrated teeth, especially inan industrial environment. Such difficulties cause inefficiencies thatare undesirable in an industrial environment.

It would be desirable to provide a modular tooling apparatus thatprovides a quick and simple adjustment mechanism for providing numerous,multi-axis adjustments of a modular tool without the risk of the modulartooling apparatus slipping and misaligning.

SUMMARY

The present invention provides a modular tooling apparatus havingcontoured surfaces for providing orbital, rotational, and linearadjustment of a modular tool. The modular tooling apparatus of thepresent invention provides a base coupling connectable to a manipulator,wherein the base coupling has a first contoured surface. A lockingmember provides a second and third contoured surface wherein the secondcontoured surface is matingly and adjustably connected to the firstcontoured surface of the base coupling for rotational adjustment of thebase coupling about a longitudinal axis. A modular tool having a fourthcontoured surface is matingly and adjustably connected to the thirdcontoured surface of the locking member to provide rotational adjustmentof the modular tool about the longitudinal axis.

BRIEF DESCRIPTION OF THE DRAWINGS

The various other uses of the present invention will become moreapparent by referring to the following detailed description and drawingsin which:

FIG. 1 is a perspective view showing the modular tooling apparatus ofthe present invention;

FIG. 2 is an exploded view showing the modular tooling apparatus of thepresent invention;

FIG. 3 is a perspective view of a rack of the modular tooling apparatusof the present invention;

FIG. 4 is a perspective view of a substantially T-shaped slide of themodular tooling apparatus of the present invention;

FIG. 5 is a perspective view of the base coupling of the modular toolingapparatus of the present invention;

FIG. 6 is a perspective view showing the contoured surface on a spacerof the modular tooling apparatus of the present invention;

FIG. 7 is an exploded view showing the spacer and the contoured surfacesof the modular tooling apparatus of the present invention;

FIG. 8 is a perspective view of the boom rod of the modular toolingapparatus of the present invention;

FIG. 9 is a perspective of the telescopic boom rod or the modulartooling apparatus of the present invention;

FIG. 10 is a perspective view of a second embodiment of the presentinvention showing an orbital adjustment of the modular tooling apparatusconnected to a flange mount;

FIG. 11 is a perspective view of the second embodiment of the presentinvention showing an orbital adjustment of the modular tooling apparatusconnected to a quick disconnect;

FIG. 12 is a front plan view of the second embodiment of the presentinvention showing the orbital adjustment of the modular toolingapparatus;

FIG. 13 is a perspective view of a third embodiment of the modulartooling apparatus of the present invention having orbital and linearadjustment;

FIG. 14 is a perspective view of a fourth embodiment of the modulartooling apparatus of the present invention having orbital and linearadjustment;

FIG. 15 is a perspective view of a fifth embodiment of the modulartooling apparatus of the present invention having a locking capassembly;

FIG. 16 is a right sided exploded view of the fifth embodiment of themodular tooling apparatus of the present invention having a locking capassembly; and

FIG. 17 is a left sided exploded view of the fifth embodiment of themodular tooling apparatus of the present invention having a locking capassembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention provides a modular tooling apparatus 10 thatprovides orbital, rotational, and linear spatial adjustments to at leastone conventional modular tool 12 connected to the modular toolingapparatus 10. As seen in FIGS. 1 and 2, the modular tooling apparatus 10may be connected to a male portion 14 of a quick disconnect (not shown)which in turn may be received by a female portion (not shown) of thequick disconnect. The female portion of the quick disconnect isconnected to a manipulator, such as a robotic arm (not shown). The maleportion 14 of the quick disconnect may be connected to a rack ormounting member 16 which in turn provides linear adjustment to a basecoupling 18 that is releasably and adjustably connected to the rack 16.A boom arm 20 may be releasably and adjustably connected to the basecoupling 18 through mating contoured surfaces 22 formed between the basecoupling 18 and the boom arm 20. The boom arm 20 extends away from thebase coupling 18 wherein a substantially 90° elbow coupling 24 isreleasably and adjustably connected to the end of the boom arm 20through a second set of contoured surfaces 26. A telescopic boom arm 32having a shovel arm 28 may then be connected to the elbow coupling 24through the use of a third set of contoured surfaces 30. The telescopicboom arm 32 provides linear and rotational adjustment of the shovel arm28 along a longitudinal axis of the telescopic boom arm 32. A modulartool 12, such as a shovel 34, may be connected to the end of the shovelarm 28 for engaging a work piece (not shown). Other modular tools 12 mayinclude pneumatic grippers, pneumatic clamps, vacuum cups, and othermaterial-handling devices. Similar assemblies comprising the same ordifferent combinations of the base coupling 18, the boom rod 20, theelbow coupling 24, the telescopic boom arm 32, the shovel arm 28, andthe shovel 34 may be attached to the rack 16, as previously described,so as to provide for the support and positioning of multiple modulartools 12.

In order to provide the modular tooling apparatus 10 with a first degreeof linear adjustment, the rack 16 is positioned and connected to themale portion 14 of the quick disconnect through the use of aconventional fastener 36 and a pair of dowel rods 38. The rack 16 has asubstantially rectangular configuration with a substantially T-shapedslot 40 extending the length of the rack 16, as seen in FIGS. 1-3. Aside 42 of the rack 16 is open to the T-shaped slot 40 and has acontoured surface, such as serrated teeth 44. The serrated teeth 44extend substantially linearly on both sides of the T-shaped slot 40along the entire length of the side 42 of the rack 16. The rack 16 maybe fabricated from a high strength, lightweight material, such asaluminum.

To allow for linear adjustment of the base coupling 18 relative to therack 16, a substantially T-shaped slide 46 matingly and slidinglyengages the T-shaped slot 40 formed in the rack 16, as seen in FIGS.1-4. The T-shaped slide 46 has a threaded aperture 47 formed therein forreceiving a conventional fastener 48 which extends through an aperture49 formed through a first side 50 to a second side 55 of the basecoupling 18, as seen in FIGS. 1-2 and 5. The base coupling 18 has asubstantially trapezoidal shape wherein the first side 50 of the basecoupling 18 has two substantially parallel rows of serrated teeth 52formed therein with a substantially rectangular recess 54 formed betweenthe two rows of serrated teeth 52. The rectangular recess 54 in thefirst side 50 of the base coupling 18 receives a portion of the T-shapedslide 46 provided in the rack 16. By threading the fastener 48 throughthe aperture 49 of the base coupling 18 and into the threaded aperture47 provided in the T-shaped slide 46 of the rack 16, the serrated teeth52 on the base coupling 18 may be securely mated to the serrated teeth44 provided on the rack 16. A washer 56 and a spring 58 may be assembledto the fastener 48 for engaging the base coupling 18 such that the basecoupling 18 is biased against the rack 16. The spring biased forceallows the base coupling 18 to maintain engagement with the rack 16while the fastener 48 is loosened such that the base coupling 18 willnot become disengaged from the rack 16. Once the fastener 48 isloosened, the user need only pull the base coupling 18 against thebiasing force of the spring 58 in order to disengage the serrated teeth52 of the base coupling 18 from the serrated teeth 44 of the rack 16 soas to linearly adjust the position of the base coupling 18 relative tothe rack 16. Thus, the base coupling 18 may be adjusted linearly along alongitudinal axis of the rack 16 as shown by arrow 59.

In order to provide orbital adjustment of the boom arm 20 relative tothe base coupling 18, the contoured surfaces 22 provide a tooth insertassembly 60 that is connected to and between a third side 59 of the basecoupling 18 and one end of the boom arm 20. The tooth insert assembly 60includes a first tooth insert 62 having a substantially cylindricalconfiguration with a contoured surface, such as serrated teeth 64,formed in a substantially circular configuration on one side of thefirst tooth insert 62 and facing away from the base coupling 18, as seenin FIGS. 1-2 and 6-7. An opposite side of the first tooth insert 62 isadjacent the third side 59 of the base coupling 18 and provides aprojection 66 having a substantially oval configuration. The projection66 on the first tooth insert 62 is received by a substantially ovalrecess 68 formed in the third side 59 of the base coupling 18. Theserrated teeth 64 of the first tooth insert 62 matingly engage acontoured surface, such as serrated teeth 70, formed on one side of asubstantially cylindrical spacer or locking member 72 of the toothinsert assembly 60. The serrated teeth 70 on the spacer 72 are formed ina substantially circular manner as similarly described on the firsttooth insert 62. The spacer 72 also has another contoured surface, suchas serrated teeth 74, formed on the opposite side of the spacer 72. Theserrated teeth 74 are formed in a substantially circular manner, assimilarly described with the serrated teeth 70 of the spacer 72. Theserrated teeth 74 of the spacer 72 matingly engage a contoured surface,such as serrated teeth 76, formed on a second tooth insert 78 of thetooth insert assembly 60. The second tooth insert 78 is similar to thefirst tooth insert 62 in that it also provides a substantially ovalprojection 80 extending from an opposite side of the second tooth insert78 from that of the serrated teeth 76. The oval projection 80 on thesecond tooth insert 78 is matingly received by a substantially ovalrecess 82 provided on one end of the boom arm 20, as seen in FIGS. 1-2and 8. The boom arm 20, the second tooth insert 78, the spacer 72, thefirst tooth insert 62, and the third side of the base coupling 18 allprovide apertures that are coaxially aligned along a common longitudinalaxis 84. A conventional fastener 86 extends along the axis 84 throughthe apertures of the boom arm 20 and the tooth insert assembly 60 andthreads into a threaded aperture 87 provided in the base coupling 18.The fastener 86 adjustably and releasably connects the boom arm 20 tothe base coupling 18 through the use of the tooth insert assembly 60. Atubular sleeve 89 extends through the tooth insert assembly 60 along thelongitudinal axis 84 and receives the fastener 86. A spring 88 and awasher 90 may be assembled to the fastener 86 so as to bias the boom arm20 against the tooth insert assembly 60 thereby biasing the tooth insertassembly 60 against the base coupling 18. This helps to secure theposition of the boom arm 20, relative to the tooth insert assembly 60and relative to the base member 18, upon the loosening of the fastener86. A spring 92 and snap ring 94 are also provided between the firsttooth insert 62 and the spacer 72 of the tooth insert assembly 60wherein the snap ring 94 is seated in a recess 95 of the sleeve 89. Thespring 92 biases the spacer 72 toward the second tooth insert 78 andaway from the first tooth insert 62. This helps maintain the position ofthe first tooth insert 62, the spacer 72, and the second tooth insert 78upon the loosening of the fastener 86.

To provide incremental adjustment of the base coupling 18 relative tothe boom arm 20, the serrated teeth 70, 74 on opposite sides of thespacer 72 of the tooth insert assembly 60 are offset by 0.6°, as seen inFIGS. 6-7. Thus, the serrated teeth 70 on the first side of the spacer72 are spaced at 15° angles so as to provide twenty-four (24) teeth 70about the substantially circular spacer 72 which matingly engage theserrated teeth 64 of the first tooth insert 62 of the tooth insertassembly 60. The serrated teeth 74 on the opposite side of the spacer 72are spaced at 14.4° angles, thereby providing a total of twenty-five(25) serrated teeth 74 on the opposite side of the circular spacer 72.The serrated teeth 74 on the spacer 72 matingly engage the serratedteeth 76 provided on the second tooth insert 78 of the tooth insertassembly 60. The offset angles on the spacer 72 of the tooth insertassembly 60 provide a multitude of rotational adjustments between thebase coupling 18 and the boom arm 20, as shown by arrow 97.

In order to have a reference as to the position of the base coupling 18and the boom arm 30, the spacer 72 has alphanumeric indicia 96 formed onthe outer surface of the spacer 72. The alphanumeric indicia 96 providea different letter 98 at each root of the serrated teeth 74 on one sideof the spacer 72. A different number 100 is provided at every root ofthe serrated teeth 70 on the opposite side of the spacer 72. A referenceindicator 102 is provided on an outer surface of the first tooth insert62 of the tooth insert assembly 60, and a second reference indicator 104is provided on an outer surface of the second tooth insert 70 of thetooth insert assembly 60. The reference indicators 102, 104 arefabricated from a narrow piece of raised material attached to the outersurfaces of the first and second tooth inserts, 60, 78, respectively.

By having the serrated teeth 70, 74 of the spacer 72 spaced at 15°intervals on the first side of the spacer 72 and at 14.4° intervals onthe second side of the spacer 72, rotational or orbital adjustment ofthe base coupling 18 relative to the boom arm 20 may be provided atevery 0.6 degrees of rotational interval. Thus, the modular toolingapparatus 10 provides for six hundred (600) different incrementalrotational adjustments of the base coupling 18 relative to the boom arm20. For instance, by placing the reference indicator 102 on the firsttooth insert 62 on the numeral “1” on the first side of the spacer 72,the reference indicator 104 on the second tooth insert 78 may be placedon any of the twenty-four (24) letters 98 (letters “I” and “O” have beeneliminated in order not to cause confusion with the numerals “1” and“0”) to provide for twenty-four (24) different incremental positionswhen the reference indicator 102 on the first tooth insert 62 is on thenumber “1”. When the reference indicator 102 on the first tooth insert62 is placed on the number “2” on the first side of the spacer 72, thereference indicator 104 on the second tooth insert 78 may be moved toany of the twenty-four (24) letters 98 on the second side of the spacer72 to provide an additional twenty-four (24) incremental positions. Thisprocess may continue in order to realize all of the six hundred (600)positions of incremental adjustment.

In order to further extend the modular tooling 12, the end of the boomarm 20 opposite the base coupling 18 is connected to a tooth insertassembly 106 that is similar to the tooth insert assembly 60. That is,the end of the boom arm 20 has a substantially oval recess 107 formatingly receiving a substantially oval projection provided on a firsttooth insert of the tooth insert assembly 106. The tooth insert assembly106 is similarly connected to the 90° elbow coupling 24 in that theelbow coupling 24 provides a substantially oval recess for matinglyreceiving a substantially oval projection provided on a second toothinsert of the tooth insert assembly 106. The elbow coupling 24 has afastener 110 which extends through an aperture provided in a first sideof the elbow coupling 24 and through the tooth insert assembly 106. Thefastener 110 also threads into a threaded aperture 108 provided in theend of the boom rod 20. By loosening the fastener 110, the elbowcoupling 24 may be rotatably adjusted with respect to the boom arm 20 byrotating the serrated teeth within the tooth insert assembly 106. Sincethe serrated teeth in tooth insert assembly 106 are offset, as describedin tooth insert assembly 60, the elbow coupling 24 will have 600positions of rotational adjustment with respect to the boom arm 20, asshown by arrow 111.

To connect the telescopic boom arm 32 to the elbow coupling 24, theopposite side of the elbow coupling 24 is connected to a tooth insertassembly 112 which is similar to the tooth insert assembly 60 previouslydescribed. Thus, the elbow coupling 24 provides a substantially ovalrecess that matingly receives a substantially oval projection providedon a first tooth insert of the tooth insert assembly 112. The toothinsert assembly 112 is connected to the boom arm 32 by the boom arm 32having a substantially oval recess 113 that matingly receives asubstantially oval projection on the second tooth insert of the toothinsert assembly 112, as seen in FIGS. 1-2 and 9. A conventional fastener114 extends through a coaxial aperture extending through the end of theboom arm 32 and through the tooth insert assembly 112. The fastener 114also extends and threads into a threaded aperture provided in the elbowcoupling 108 in order to connect and secure the above listed elements. Aspring 116 and a washer 118 may be assembled to the fastener 114 to biasthe boom arm 32 toward the tooth insert assembly 112, as previouslydescribed in the similar configurations. By loosening the fastener 114,the serrated teeth in the tooth insert assembly 112 may be rotatedrelative to one another to allow for 600 rotational adjustments of theboom arm 32 relative to the elbow coupling 108, as shown by arrow 120.

To provide further linear and rotational adjustment of the modulartooling 12, the boom arm 32 may have a telescopic adjustment wherein afirst portion 122 of the boom arm 32 receives a second portion or theshovel arm 28 of the boom arm 32. The first portion 122 of the boom arm32 has a substantially cylindrical configuration with slots 126extending through the walls at one end of the first portion 122 of theboom arm 32. The slots 126 of the first portion 122 of the boom arm 32allow the end of the first portion 122 to expand and receive the secondportion 28 of the boom arm 32. A clamp 128 extends over the slottedportion of the first portion 122 of the boom arm 32. A conventionalfastener 130 extends through apertures provided in a clamp 128 so as toreleasably secure the second portion 28 of the boom arm 32 within thefirst portion 122 of the boom arm 32. When the clamp 128 is loosened byloosening the fastener 130, the second portion 28 of the boom arm 32 maybe rotated or adjusted linearly along the longitudinal axis of the boomarm 32. The shovel 34 is connected to the end of the second portion 28of the boom arm 32 through the use of a conventional fastener 132. Aspreviously noted, any form of modular tooling 12 may be connected to theboom arm 32. Thus, the telescopic feature of the boom arm 32 allows forlinear adjustment, as shown by arrow 134, and rotational adjustment, asshown by arrow 136, along and about the longitudinal axis of the boomarm 32.

In another embodiment, the tooth insert assembly 60, as previouslydescribed, may be utilized to provide multiple orbital adjustments ofthe modular tooling apparatus 10. As seen in FIGS. 11-12, a quickdisconnect 138 may be connected to a manipulator (not shown), such as arobotic arm or transfer rail/beam, or the modular tooling apparatus 10may be connected to a manipulator by a flange mount 139, as seen in FIG.10. As seen in FIGS. 11-12, the quick disconnect 138 has a femaleportion 140 that is connected to the manipulator through the use ofconventional fasteners. A male portion 142 of the quick disconnect 138is received by the female portion 140 of the quick disconnect 138. Thequick disconnect 138 may provide pneumatic and electrical connectionsbetween the female and male portions 140, 142 of the quick disconnect138.

To connect the modular tooling apparatus 10 to the quick disconnect 138,as seen in FIGS. 11-12, or to the flange mount 139 as seen in FIG. 10, atooth insert assembly 144, similar to the tooth insert assembly 60previously described, is connected to the end of the male portion 142 ofthe quick disconnect 138 or to the flange mount 139. The male portion142 of the quick disconnect 138, as seen in FIGS. 11-12, and the flangemount 139, as seen in FIG. 10, both have a substantially oval recess forreceiving a substantially oval projection extending from a first toothinsert of the tooth insert assembly 144. The tooth insert assembly 144is also connected to linkage bar 146 through the use of a conventionalfastener 148. The fastener 148 extends through a coaxial apertureextending through the linkage bar 146, the tooth insert assembly 144,and the male portion 142 of the quick disconnect 138 of the flange mount139. Both the male portion 142 of the quick disconnect 138 and theflange mount 139 have threaded apertures for threadingly receiving thefastener 148. A spring (not shown) and a washer (not shown) may also beconnected to the fastener 148, as previously described in a similarconstruction, so as to bias the linkage bar 146 toward the tooth insertassembly 144. By loosening the fastener 148, the tooth insert assembly144 may be rotated to provide orbital adjustment of the linkage bar 146,as shown by the rotational axis 150 in FIG. 12, relative to the maleportion 142 of the quick disconnect 138. Since the serrated teeth of thetooth insert assembly 144 are offset as described in the tooth insertassembly 60, the linkage bar 146 will have 600 incremental rotationaladjustments relative to the quick disconnect 138 or flange mount 139.

The linkage bar 146 has a substantially rectangular configuration withrounded ends 152 at each end of the linkage bar 146. Opposite the firstend of the linkage bar 146 is a second end that is connected to a toothinsert assembly 154 which is similar to the tooth insert assembly 60.That is, the linkage bar 146 has a substantially oval recess formatingly receiving a substantially oval projection on a first toothinsert on the tooth insert assembly 154. The tooth insert assembly 154connects the linkage bar 146 to a second similar linkage bar 156 havinga similar configuration to that of the linkage bar 146. That is, thelinkage bar 156 has a substantially oval recess for receiving asubstantially oval projection on a second tooth insert of the toothinsert assembly 154. A conventional fastener 158 extends through acoaxial aperture extending through the linkage bar 146, the tooth insertassembly 154, and a first end of the linkage bar 156 where the fastener158 threads into a threaded aperture provided in the first end linkagebar 156. A spring (not shown) and a washer (not shown) may also beassembled to the fastener 158, as previously described in similarconfigurations, wherein the linkage bar 156 is biased toward the toothinsert assembly 154. When the fastener 158 is loosened, the serratedteeth of the tooth insert assembly 154 may be rotated to provide 600orbital adjustments of the linkage bar 156 relative to the linkage bar146 due to the offset serrated teeth in the tooth insert assembly 154,as previously described in the tooth insert assembly 60.

In order to provide orbital rotational and linear adjustment to themodular tool 12, a second end of the linkage bar 156, which is oppositethe first end of the linkage bar 156, may have a telescopic boom arm160, as similarly described in the boom arm 32, connected to the end ofthe linkage bar 156. The second end of the linkage bar 156 has asubstantially oval recess that receives a substantially oval projectionprovided on the boom arm 160. A fastener extends through the second endof the linkage bar 156 and threaded into a threaded aperture in the boomarm 160 to secure the boom arm 160 to the linkage bar 156. Thus, thelinkage bar 156, in combination with the linkage bar 146, may allow fororbital adjustment of the mounting tool 12, as shown in radial axes 161and 162 of FIG. 12. The telescopic boom arm 160 also provides linear androtational adjustment of the modular tool 12, as previously describedwith the similar telescopic boom arm 32.

In yet another embodiment, the modular tooling apparatus 10 provides amethod for providing linear and orbital adjustment of the modulartooling 12, as seen in FIGS. 13 and 14. The modular tooling apparatus 10provides a 90° elbow bracket 164 that is releasably and adjustablyconnected to a mounting rail 166. The mounting rail 166 provides asubstantially T-shaped slot 168 for receiving a substantially T-shapedslide 170. The T-shaped slide 170 is captured within the T-shaped slot168 of the mounting rail 166 such that the T-shaped slide 170 may slidealong the T-shaped slot 168 of the mounting rail 166. A conventionalfastener 172 extends through an aperture provided in the 90° elbowbracket 164 and threads into a threaded aperture provided in theT-shaped slide 170. The 90° elbow bracket 164 extends across the openingcreated by the T-shaped slot 166 in the mounting rail 166 such that whenthe fastener 172 is threaded into the threaded aperture of the T-shapedslide 170, the T-shaped slide 170 and the 90° elbow bracket 164 tightenagainst the mounting rail 166 so as to secure the 90° elbow bracket 164in a stationary position relative to the mounting rail 166. Thus, whenthe fastener 172 is loosened, the 90° elbow bracket 164 may be adjustedlinearly along the longitudinal axis of the mounting rail 166 by slidingthe T-shaped slide 170 along the mounting rail 166, as shown by arrow173.

The other end of the 90° elbow bracket 164 extends outward away from themounting rail 166 and has an aperture extending there through forreceiving a fastener 176. The fastener 176 also extends through a pairof substantially circular disks 178, 180 having opposing and matingserrated teeth 182, 184 formed in a substantially circular configurationon each of the circular disks 178, 180. The fastener 176 extends throughcoaxial apertures extending through of the 90° elbow bracket 164 andthrough apertures provided in each of the circular disks 178, 180. Thefastener 176 also extends into a substantially T-shaped slide 186 thatis slidably captured within a substantially T-shaped slot 188 formed ina substantially rectangular linkage rail 190. When the fastener 176 isthreaded into a threaded aperture in the T-shaped slide 186, theT-shaped slide 186 and the circular disks 178, 180 tighten against thelinkage rail 190 so as to secure the 90° elbow bracket 164 in a fixedposition relative to the linkage rail 190. However, when the fastener176 is loosened, the T-shaped slide 186 is allowed to move linearlyalong the linkage rail 190, and the circular disk 178, 180 are allowedto rotate relative to one another so as to allow the linkage rail 190 torotate relative to the mounting rail 166, as indicated by arrow 192.Although the circular disks 178, 180 do not include a spacer havingserrated teeth there between, it should be known that the presentinvention anticipates using a tooth insert assembly 60 in the presentembodiment, as previously described.

In order to provide further adjustment of the modular tooling 12, themodular tooling apparatus 10 provides an additional linkage rail 194that is similar to the linkage rail 190. The linkage rail 194 alsoprovides a T-shaped slot 196 and a substantially T-shaped slide (notshown) similar to that previously described in the linkage rail 190. Apair of circular disks 200, 202, similar to disks 178, 180, between thelinkage rails 190, 194 are also provided with each disk 200, 202 havinga circular array of serrated teeth 204, 206. The circular disk 200 ismounted adjacent the T-shaped slide provided in the linkage rail 194,and the circular disk 202 is mounted adjacent the T-shaped slot 188 ofthe linkage rail 190. A conventional fastener 210 extends coaxiallythrough apertures provided in the T-shaped slide 208, the circular disk200, 202, and the substantially T-shaped slide 198 provided in thelinkage rail 194. There is no T-shaped slide provided in linkage rail190 because the fastener 210 must extend through the linkage rail 190 toprovide access to the fastener 210, therefore the disks 200, 202 cannotmove linearly along the linkage rail 190. However, when the fastener 210is loosened, the T-shaped slide may slide along the linkage rail 194 toprovide linear adjustment along the mounting rail 194, as indicated byarrow 198. The circular disks 200, 202 may also rotate relative to oneanother thereby providing rotational or orbital adjustment of thelinkage rail 194 relative to the linkage rail 190, as indicated by arrow212. When the fastener 210 is tightened, the circular disks 200, 202 andsubstantially T-shaped slides 198, 208 are secured in a fixed positionrelative to the linkage rails 194, 190. However, since the fastener 210must pass through an aperture provided in a wall of the linkage rail 190in order to provide the user with access to the fastener 210, thelinkage rail 194 cannot be adjusted linearly along the linkage rail 190.

To secure the modular tooling 12 to the linkage rail 194, a 90° elbowbracket 214 is utilized at one end of the linkage rail 194, as seen inFIG. 13. The 90° elbow bracket 214 has a pair of circular disks 216, 218mounted between the 90° elbow bracket 214 and the linkage rail 194. Eachof the circular disks 216, 218 have a circular array of mating serratedteeth 220, 222 similar to disks 178, 180. The circular disk 218 ismounted adjacent a substantially T-shaped slot 196 provided in thelinkage rail 194. A conventional fastener 226 extends coaxially throughan aperture provided in the mounting rail 194, through the T-shapedslide 224, the circular disks 216, 218, and the 90° elbow bracket 214.Again, no T-shaped slide is utilized due to the fastener 226 extendingthrough the linkage rail 194. However, when the fastener 226 isloosened, the serrated disk 216, 218 may rotate relative to one anotherthereby providing rotational adjustment of the modular tooling 12relative to the linkage rail 194, as indicated by arrow 227. When thefastener 226 is tightened, the circular disks 216, 218 are broughttogether to allow the serrated teeth 220, 222 of the disks 216, 218 tomate, thereby securing the 90° elbow bracket 214 in a stationaryposition relative to the linkage rail 194.

To provide rotational adjustment to the modular tool 12, an opposite endof the 90° elbow bracket 214 provides a substantially circular disk 228having a circular array of serrated teeth 230 formed thereon. Themodular tool 12 has a mounting bracket 232 connected to the modular tool12 by four conventional fasteners 234. The mounting bracket 232 also hasa circular array of serrated teeth 236 mounted thereon for matinglyengaging the serrated teeth 230 provided on the circular disk 228 of the90° elbow bracket 214. A conventional fastener (not shown) extendscoaxially through an aperture provided in the 90° elbow bracket 214, thecircular disk 228, and the mounting bracket 232. When the fastener isloosened, the serrated teeth 230, 236 may be allowed to rotate relativeto one another to provide for rotational adjustment of the modular tool12, as indicated by an arrow 240. When the fastener 238 is tightened,the serrated teeth 230, 236 are matingly secured against one anotherthereby allowing the modular tool 12 to be maintained in a stationaryposition relative to the 90° elbow bracket.

In an alternative embodiment shown in FIG. 14, an additional linkagerail 242 may be connected to linkage rail 194 before connecting theelbow coupling 214 to the modular tool 12. The same construction aslinkage members 190 and 194 is utilized to provide the modular toolingapparatus with an additional degree of orbital and linear adjustment ofthe modular tool.

In another embodiment of the of the present invention, the tooth insertassembly 60 can be replaced in a modular tooling apparatus 300 by alocking cap assembly 302, as shown in FIG. 15. In the modular toolingapparatus 300, the locking cap assembly 302 may be utilized to assist inconnecting the modular tool 12 to a quick disconnect, as similarlydescribed in previous embodiments, while providing orbital androtational adjustment of the modular tool 12. The locking cap assembly302 is similar to the tooth insert assembly 60 in that two sets ofcontoured surfaces having serrated teeth with different number of teethare employed to achieve fine positional control and ease of adjustmentof the locking cap assembly 302; however, the methods of adjustment aredifferent from those of the tooth insert assembly 60.

FIGS. 16 and 17 show exploded views of the locking cap assembly 302,which includes a mounting member or base coupling 304 having asubstantially cylindrical extension 306 having a face with four slots308 formed therein along a longitudinal axis 310. The mounting member304 may be connected to a boom rod, coupling, and/or quick disconnectwhich in turn is connected to a manipulator. The locking cap assembly302 also includes a moveable member 312 which in turn is connected tothe modular tool 12. The moveable member 304 has an aperture 314extending there through for rotatably receiving the cylindricalextension 306 of the mounting member 304. The moveable member 304 has acontoured surface having serrated teeth 316 radially formed therein in asubstantially cylindrical manner. The mounting member 304 also has asubstantially cylindrical base member 318 having four tabs 320 formed onone end of the base member 318 that matingly engage the slots 308 of thecylindrical extension 306 of the mounting member 304 in a fixedrelationship. The base member 318 is also partially received within theaperture 314 provided in the moveable member 304. The base member 318also a contoured surface having serrated teeth 322 radially formed in asubstantial cylindrical and extending from the opposite end of the basemember 318 from the tabs 320. The serrated teeth 322 of the base member318 fit within the serrated teeth 316 of the moveable member 312 withoutinterfering with its movement. The locking cap assembly 302 furtherincludes a substantially cylindrical locking cap or locking member 326having one contoured surface of serrated teeth 328 and a secondcontoured surface of serrated teeth 330 formed on one end of the lockingcap 326. The serrated teeth 328, 330 are radially formed therein in asubstantial cylindrical manner and are coaxially aligned and concentricwith one another wherein serrated teeth 330 has a larger diameter thanserrated teeth 328. The locking cap 326 is releasably engageable tolocking cap assembly 302 by a conventional fastener 332 which passesthrough appropriately sized apertures in locking cap 326, spacers 324,moveable member 312 and base member 318 to be attached to a threadedaperture 334 in the mounting member 304 along the longitudinal axis 310.

To secure the locking cap assembly 302 and prevent the mounting member304 from moving in relation to the moveable member 312, the fastener 332is threaded into the threaded aperture 334 causing the locking cap 326to engage the serrated teeth 328 on the locking cap 326 with theserrated teeth 322 of the base member 318 and engage the serrated teeth330 of the locking cap 326 with the serrated teeth 316 of the moveablemember 312. When the fastener 332 is tightened against the locking cap326, the engagement of the first slots 308 and the second tabs 320, theserrated teeth 322, 328, and the serrated teeth 316, 330 preventmounting member 304 from moving in relation to the moveable member 312.

To adjust the locking cap assembly 302 and change the geometricrelationship between the mounting member 304 and the moveable member312, the fastener 332 is threadingly loosened to permit disengagement ofthe serrated teeth 328 in the locking cap 326 from the serrated teeth322 on the base member 318 and the serrated teeth 330 of the locking cap326 from the serrated teeth 316 of the moveable member 312 withoutremoving the fastener 332 completely from the threaded aperture 334. Themounting member 304 and the moveable member 312 are then free to move inrelation to each other about the longitudinal axis 310. Adjustment canbe accomplished by an operator manipulating the mounting member 304 andthe moveable member 312 by hand to the desired position. The locking cap326 can be then rotated about the longitudinal axis 310 to find alocation where the serrated teeth 328 of the locking cap 326 can engagethe serrated teeth 322 of the base member 318 and the serrated teeth 330of the locking cap 326 can engage the serrated teeth 316 of the moveablemember 312, simultaneously. This is possible since the combination ofunequal numbers of serrated teeth on the contoured surfaces providesadjustment to within about 0.6 degrees by rotating the locking cap 326with respect to the serrated teeth 322 of the base member 318 and theserrated teeth 316 of the moveable member 312. The locking cap assembly302 can then fix the relative position of the mounting member 304 andthe moveable member 312 in this position by threadingly tightening thefastener 332, thereby maintaining the adjusted relationship between themounting member 304 and the moveable member 312.

Since the serrated teeth 328 of the locking cap 326 and the serratedteeth 322 of the base member 318 have a first number of teeth, and theserrated teeth 330 of the locking cap 326 and the serrated teeth 316 ofthe moveable member 312 have a second number of teeth, the angularresolution at which the locking cap assembly 302 can fix the moveablemember 312 and the mounting member 304 is a function of the ratio of thefirst and second numbers of teeth. For example, if the serrated teeth328, 322 have 24 teeth and the serrated teeth 330, 316 have 25 teeth,the angular resolution of the locking cap assembly 302 is about 0.6degrees yielding 600 different positions at which the locking capassembly 302 can be set within its 360° rotation. To find the correctposition at which the serrated teeth 328, 330 of the locking cap 326engage the serrated teeth 328 of the base member 318 and the serratedteeth 316 of the moveable member 312, the locking cap 326 is rotateduntil the best fit between the serrated teeth 328, 322, 330, 316 isfound.

Different embodiments of the locking cap assembly 302 can also include abiasing element which helps to maintain engagement of appropriatecontoured surfaces during the adjustment process. Inclusion of springsthrough which the fastener 332 passes on the longitudinal axis 310between the fastener 332 and the locking cap 326 can cause the lockingcap 326 to be biased against the moveable member 312 and the base member318 unless a user is actively disengaging the locking cap 326.

In operation, the modular tooling apparatus 10 of the present inventionis assembled in a manner that allows the modular tooling 12 to reach andengage the appropriate work piece when manipulated by the manipulator.The modular tooling apparatus 300, as previously described, may beadjusted linearly and orbitally to allow the modular tooling 12 to be ina proper position relative to the work piece.

While the invention has been described in connection with certainembodiments, it is to be understood that the invention is not to belimited to the disclosed embodiments but, on the contrary, is intendedto cover various modifications and equivalent arrangements includedwithin the spirit and scope of the appended claims, which scope is to beaccorded the broadest interpretation so as to encompass all suchmodifications and equivalent structures as is permitted under the law.

1-18. (canceled)
 19. A modular tooling apparatus comprising: a base coupling connectible to a manipulator; a first linkage member adjustably connected to the base coupling for rotational adjustment about a first axis; and a second linkage member adjustably connected to the first linkage member for rotational adjustment about a second axis, wherein the rotational adjustment of the first linkage member about the first axis and the rotational adjustment of the second linkage member about the second axis combine to provide orbital adjustment of the second linkage member about the first axis.
 20. The modular tooling apparatus of claim 19, wherein the first axis and the second axis are substantially parallel to one another.
 21. The modular tooling apparatus of claim 19, wherein the first axis and the second axis are radially spaced from one another.
 22. The modular tooling apparatus of claim 19, wherein the first linkage member and the second linkage member have substantially rectangular configurations.
 23. The modular tooling apparatus of claim 19, wherein the first linkage member and the second linkage member have substantially rectangular configurations with arcuate ends.
 24. The modular tooling apparatus of claim 19, wherein a modular tool is connected to the second linkage member.
 25. A modular tooling apparatus comprising: a base coupling connectible to a manipulator and having a first contoured surface; a first linkage member having a second contoured surface and a third contoured surface, wherein the second contoured surface is matingly and adjustably connected to the first contoured surface of the base coupling for rotational adjustment of the first linkage member about a first axis; and a second linkage member having a fourth contoured surface matingly and adjustably connected to the third contoured surface of the first linkage member for rotational adjustment of the second linkage member about a second axis, wherein the first axis and the second axis are substantially parallel to one another.
 26. The modular tooling apparatus of claim 25, wherein the first axis and the second axis are radially spaced from one another.
 27. The modular tooling apparatus of claim 25, wherein the second contoured surface and the third contoured surface of the first linkage member are in the same plane.
 28. The modular tooling apparatus of claim 25, wherein the first linkage member and the second linkage member have substantially rectangular configurations.
 29. The modular tooling apparatus of claim 25, wherein the first linkage member and the second linkage member have substantially rectangular configurations with arcuate ends.
 30. The modular tooling apparatus of claim 25, wherein the rotational adjustment of the first linkage bar about the first axis and the rotational adjustment of the second linkage bar about the second axis combine to provide orbital adjustment of the second linkage bar about the first axis.
 31. The modular tooling apparatus of claim 25, wherein the second contoured surface and the third contoured surface extend in the same direction.
 32. The modular tooling apparatus of claim 25, wherein the first contoured surface and the third contoured surface extend in the same direction.
 33. The modular tooling apparatus of claim 25, wherein the first contoured surface, the second contoured surface, the third contoured surface, and the fourth contoured surface each have a base and a plurality of ridges extending radially away from the base.
 34. The modular tooling apparatus of claim 33, wherein the plurality of ridges on the second contoured surface and the plurality of ridges on the third contoured surface extend in the same direction.
 35. The modular tooling apparatus of claim 34, wherein the plurality of ridges on the first contoured surface and the plurality of ridges on the fourth contoured surface extend in a direction that is substantially opposite as the direction that the plurality of ridges on the second contoured surface and the plurality of ridges on the second contoured surface extend.
 36. The modular tooling apparatus of claim 25, wherein a modular tool is connected to the second linkage member. 